Electronic switching device and system

ABSTRACT

The present invention is directed to an electronic switch device that includes a front cover assembly having a user interface, a back body assembly, and a plurality of terminals configured to be coupled to an AC power source and the load. A circuit assembly is coupled to the plurality of terminals. The circuit assembly includes a relay switch having a commutator and a set of contacts. The relay switch is characterized by a predetermined commutator period, the predetermined commutator period being substantially the commutator travel time between the set of contacts during a relay switch actuation. The circuit assembly further includes an actuation circuit configured to provide a constant current actuation signal that energizes the relay switch in response to an input stimulus via the user interface such that an end of the predetermined commutator period substantially coincides with a predetermined point in an AC power cycle.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to electrical devices, andparticularly to electrical switch devices.

2. Technical Background

The conventional method for installing electrical circuits includes arough-in phase and a finish phase. In the rough-in phase, conduit orcable is disposed throughout the structure in accordance with thebuilding plans. Junction boxes are installed at appropriate locations tohouse electrical connection points where two or more conductors arespliced together. Device boxes are installed throughout the structurewhere electrical service is desired. After the boxes are placed, theelectrical wires are pulled through the conduits (if provided) and allof the circuits are bonded.

After the “rough-in” phase has been completed, the electrical wiringdevices are terminated, i.e., they are electrically connected to thewire leads. This part of the installation process is typically performedor supervised by a journeyman electrician. Subsequently, the groundstrap of the electrical wiring device is mounted to the device box. Oneor more electrical wiring devices may be mounted to a device boxdepending on its size. A single-gang device box typically accommodatesone electrical wiring device, a two-gang device box will typicallyaccommodate two electrical wiring devices; and so on and so forth. Oncean electrical wiring device is installed inside the device box, a coverplate is disposed over the electrical wiring device to “complete theelectrical enclosure” such that individuals are not exposed to “hot”electrical wiring after the electrical power is turned ON.

There are several drawbacks associated with conventional installationmethods and conventional wiring devices. Conventional wiring devicesoften do not make efficient use of space due to their one-size-fits-alldevice box designs. What is needed, for example, is an electricalswitching device that makes more efficient use of the available space,e.g., one that does not require all of the space available in a singlegang device box.

Mounting the ground strap of an electrical wiring device to the devicebox is tedious, time consuming, and therefore costly. The same can besaid of mounting the cover plate to the electrical wiring device. Inmulti-gang installations, the finished look is often ragged because theelectrical devices and the cover plates are not in alignment. Themisalignment is often in all three dimensions. Retrofitting aninstallation can also be problematic from a finished look standpointbecause the device box or an old work box may not be precisely alignedto the plane of the wall surface. Moreover, the wall surface itself maybe uneven. After remodeling a space, homeowners often seek to replace anexisting wall plate with one that better matches the new decor. Thus, ahomeowner may inadvisably remove the faceplate cover from an energizedwiring device and inadvertently become exposed to a shock hazard fromthe “hot” electrical wiring. What is needed therefore is a modularelectrical wiring device system that addresses the drawbacks articulatedabove.

Electrical switches are a well known type of electrical wiring deviceand are commonly employed as, e.g., light switches. “Toggle” switchesinclude single pole single throw (SPST) switches that are used tomechanically switch lights between an ON state and an OFF state. Onedrawback to these types of switches is that a light must turned ON/OFFfrom one location. A light may be controlled from two locations by usingthree way toggle switches, i.e., by employing two single pole doublethrow switches (SPDT). Each SPDT switch depends on the switch positionof the other. When one SPDT switch turns a light ON, it is because theswitch position of the other SPDT was in a switch position that resultedin the light being previously OFF. Thus, the two SPDT work in tandemsuch that the light may be controlled at two locations. Certain switchesof this type incorporate a bistable latching relays. Latching relaysoften include solenoids that are electrically actuated by a low powersignal. Some of the drawbacks associated with relay switches relate todegradation, fatigue, undesired arcing and excessive leakage current toground. What is needed therefore is an electrical switch that addressesthese drawbacks.

The concept of modularity may also be extended to electrical switches.As noted above, after remodeling a space, homeowners often seek toreplace an existing switch with one that better matches the new decor.Again, the homeowner may inadvisably attempt to replace the existingelectrical switch with a new device and become exposed to a shock hazardfrom the “hot” electrical wiring. A modular electrical switch thataddresses the needs previously identified is also desirable. What isalso needed is a modular electrical switch that is interchangeable;i.e., it allows for the removal of the actuator portion without becomingexposed to shock or electrocution.

SUMMARY OF THE INVENTION

The present invention is directed to an electrical switching system thataddresses the needs described above.

One aspect of the present invention is directed to an electronic switchdevice for controlling a load. The device comprises a housing assemblyincluding a front cover assembly having a user interface, a back bodyassembly, and a plurality of terminals configured to be coupled to an ACpower source and the load. A circuit assembly is coupled to theplurality of terminals. The circuit assembly includes a relay switchhaving a commutator and a set of contacts. The relay switch ischaracterized by a predetermined commutator period, the predeterminedcommutator period being substantially the commutator travel time betweenthe set of contacts during a relay switch actuation. The circuitassembly further includes an actuation circuit configured to provide aconstant current actuation signal that energizes the relay switch inresponse to an input stimulus via the user interface such that an end ofthe predetermined commutator period substantially coincides with apredetermined point in an AC power cycle.

In another aspect, the present invention is directed to an electronicswitch device that comprises a housing assembly including a plurality ofterminals configured to be coupled to an AC power source and a load. Thehousing assembly also includes a user interface and a sensitivityadjustment interface. A circuit assembly is coupled to the plurality ofterminals. The circuit assembly includes a relay switch having acommutator and a set of contacts. The relay switch is characterized by acommutator period, the commutator period being substantially thecommutator travel time between the set of contacts. The circuit assemblyalso includes a sensor detector receptor portion coupled to the userinterface and configured to sense perturbations of a signal parameter.The circuit assembly also includes a sensor detector coupled to thesensor receptor portion. The sensor detector is configured to determinewhether the perturbations of the signal parameter correspond to a switchactuation command in accordance with a detection rule. The circuitassembly also includes a regulation circuit coupled to the sensitivityadjustment interface and the sensor detector. The regulation circuit isconfigured to adjust the detection rule in accordance with a setting ofthe sensitivity adjustment interface and direct the relay switch toactuate in response to the switch actuation command in accordance with aselected sensitivity adjustment.

In yet another aspect, the present invention is directed to anelectronic switch device configured to be installed within a device box,the device comprises a housing assembly that includes a plurality ofterminals configured to be coupled to an AC power source. The housingassembly further includes a first circuit assembly coupled to theplurality of terminals. The first circuit assembly includes a relayswitch having a commutator and a set of contacts, the relay switch beingcharacterized by a commutator period, the commutator period beingsubstantially the commutator travel time between the set of contacts. Aninterchangeable switch module is configured to be coupled and decoupledfrom the housing assembly. The interchangeable switch module is selectedfrom a plurality of interchangeable switch modules. Each interchangeableswitch module is characterized by a user interface that is implementedby one of a plurality of switching technologies. The interchangeableswitch module also includes a second circuit assembly coupled to thefirst circuit assembly when the interchangeable switch module is coupledto the housing assembly. The second circuit assembly propagates aconstant current actuation signal that energizes the relay switch inresponse to an input stimulus via the user interface such that an end ofthe predetermined commutator period substantially coincides with apredetermined point in an AC power cycle.

Additional features and advantages of the invention will be set forth inthe detailed description which follows, and in part will be readilyapparent to those skilled in the art from that description or recognizedby practicing the invention as described herein, including the detaileddescription which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary of theinvention, and are intended to provide an overview or framework forunderstanding the nature and character of the invention as it isclaimed. The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The drawings illustrate various embodimentsof the invention, and together with the description serve to explain theprinciples and operation of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B are perspective views of a frame member in accordance withthe present invention;

FIGS. 2A-2D are perspective views of a modular alignment connector inaccordance with the present invention;

FIG. 3 is a detail view of the modular alignment connector depicted inFIGS. 2A-2D;

FIGS. 4A-4E are illustrative views showing installation details of theframe, modular alignment connector and electrical wiring device;

FIGS. 5A-5C are perspective views of a modular electrical wiring systemshowing an electrical switching device in conjunction with an aestheticoverlays 60 in accordance with the present invention;

FIG. 6 is a perspective view of an electronic wave switch in accordancewith one embodiment of the present invention;

FIG. 7 is an exploded view of the electronic wave switch depicted inFIG. 6;

FIGS. 8A-8B are cross-sectional views of the electronic wave switchdepicted in FIG. 6;

FIGS. 9A-9G are detail views of the cover assembly of the electronicwave switch depicted in FIG. 6;

FIGS. 10A-10B are schematic diagrams of the AC power PCB in accordancewith the present invention;

FIGS. 11A-11D are schematic diagrams of the low voltage PCB of theelectronic wave switch depicted in FIG. 7;

FIGS. 12A-12B are perspective views of an electronic tap switch inaccordance with another embodiment of the present invention;

FIGS. 13A-13B are detail views of various layers of the front coverassembly of the electronic tap switch depicted in FIGS. 12A-12B;

FIG. 14 is an exploded view of the electronic tap switch depicted inFIGS. 12-13;

FIGS. 15A-15D are cross sectional views of the electronic tap switchdepicted in FIGS. 12A-12B;

FIG. 16 is a schematic diagram of the low voltage PCB of the electronictap switch depicted in FIG. 13;

FIGS. 17A-17B are perspective views of an electronic touch switch inaccordance with yet another embodiment of the present invention;

FIG. 18 is an exploded view of the electronic touch switch depicted inFIG. 17A;

FIGS. 19A-19C are cross sectional views of the electronic touch switchdepicted in FIGS. 17A-17B;

FIG. 20 is a schematic diagram of the low voltage PCB of the electronictap switch depicted in FIG. 18;

FIG. 21 is an exploded view of the modular electrical wiring system inaccordance with another embodiment of the present invention;

FIG. 22 is a detail exploded view of the modular electrical wiringsystem shown in FIG. 21;

FIG. 23 is a front view of an electronic switch in accordance with yetanother embodiment of the present invention;

FIG. 24 is a front view of an electronic switch in accordance with yetanother embodiment of the present invention; and

FIGS. 25A-25D are directed to various embodiments of LED locator lensesin accordance with the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to the present exemplaryembodiments of the invention, examples of which are illustrated in theaccompanying drawings. Wherever possible, the same reference numberswill be used throughout the drawings to refer to the same or like parts.An exemplary embodiment of the frame is shown in FIGS. 1-4, and isdesignated throughout as reference number 10. An exemplary embodiment ofthe electrical switch device of the present invention is shown in FIG.6, and is designated generally throughout by reference numeral 100. Anexemplary embodiment of the framing system that includes the framemember, frame components, and switch 100 is shown in FIGS. 5A-5C and isdesignated generally throughout by reference numeral 500.

As embodied herein, and depicted in FIGS. 1A-1B perspective views of aframe member in accordance with the present invention are disclosed.FIG. 1A is directed to the rear side 10-2 of the frame member 10 andFIG. 1B is directed to the front side 10-1 of the frame member 10.Reference is made to U.S. patent application Ser. No. 13/680,675, filedon Nov. 19, 2012, which is incorporated herein by reference as thoughfully set forth in its entirety, for a more detailed explanation of theframing system shown in FIGS. 1-5. The frame member 10 is configured to“complete the electrical enclosure” when the modular electrical deviceis properly installed within the frame device opening 10-13. Stateddifferently, instead of using a conventional wall plate to complete theenclosure, the present invention counter-intuitively endows the framewith the function of preventing individuals from being exposed to hotelectrical wiring in the device box when the device is energized.

One way the enclosure is completed is by providing a frame enclosure lip10-5 around the perimeter of the frame. The frame lip 10-5 is configuredto abut the adjacent wall surface such that the edge of the properlyinstalled wall box cannot touch the rear side of the frame because ofthe frame lip 10-5. This is true even when old work boxes having flangesthat mount to the outer surface of the sheet rock are used. The lip 10-5does not interfere with the old work box flanges; it allows the frame 10to abut the wall surface. The frame 10 also includes a frame opening10-13. The edges of the frame opening 10-13 are configured to abutmodular alignment connectors 20, or electrical wiring devices 100, inthe manner disclosed below. Once the frame is installed and the opening10-13 is filled with one or more electrical wiring devices and/or one ormore modular alignment connectors 20, the enclosure is completed.

The frame 10 further includes interior serrated wall members 10-6 andconnector landing elements 10-7 that extend around the perimeter of theframe device opening 10-13 to form an integral rim or skirt that isinserted into the device box. The serrated wall members 10-6 aredisposed along the sides of the opening 10-13 whereas the landingelements are disposed at either end of the opening 10-13. Each landingelement 10-7 includes a ground connection tab 10-8. Thus, the region ofthe frame 10 disposed between the enclosure lip 10-5 and the integralrim (formed by 10-7 and 10-8) covers the wall surface 1. Once the wallbox screws/fasteners 10-10 (not shown) are inserted into the fastenerslots 10-12 and tightened, the only way of accessing the interior of thedevice box is via the frame opening 10-13 which is completely filled bymodular alignment connectors 20 and/or a modular wiring device 100 afterinstallation. In another embodiment, the modular wiring device may beconfigured to completely fill the enclosure.

As embodied herein and depicted in FIGS. 2A-2D, perspective views of amodular alignment connector 20 in accordance with the present inventionare disclosed. FIG. 2A shows the front major surface 20-1 of the modularalignment connector 20 when it is inserted within the opening 10-13 ofthe frame 10. The connector front surface 20-1 includes a frontconnector flange 20-6 which is configured to fit within the frameconnector seat 10-15 when the connector is disposed within the frame 10.The modular alignment connector 20 further includes bending snap arms20-3, spacer tangs 20-4, and a spacer channel 20-5 disposedtherebetween. The bending snap arms 20-3 are provided on either side ofthe connector 20 to allow the connector 20 to snap into the frame wheninserted into the opening 10-13. The spacer tang 20-4 is used to lockthe modular alignment connector 20 into the frame 10. Briefly stated,connector 20 is locked when the spacer tang 20-4 is pressed into thespacer channel 20-5 (see, e.g., FIG. 2D). As its name suggests, themodular alignment connector 20 provides a correctly sized frame opening10-13 such that various combinations of wiring devices complete theopening when they are installed in frame 10. In particular, the frameopening is configured to accommodate three “one-module” sized wiringdevices. A “two-module” sized device requires two modular alignmentconnectors 20 to complete the opening. A “three-module” sized device isinserted into the frame opening 10-13 to complete the enclosure. Thesnap connect assembly (20-3, 20-4, and 20-5) is configured to withstandat least 50 foot-pounds of pulling force.

FIG. 2B shows the modular connector 20 rotated 180° with respect to theview provided by FIG. 2A. In this view, the connector 20 is shown toinclude a front stabilizing plate 20-6 that works in conjunction withthe frame's rear connector flanges 20-7 to form a connector channel 20-8that is sized to be seated on, and grip, the frame connector landing10-7 (shown in FIGS. 1A and 1B). The stabilizing plate 20-6 is alsoconfigured to overlay a portion of frame front face 10-1 (FIG. 1B) whenthe modular alignment connector 20 is inserted into, and fully seated atthe end of the opening 10-13. Stated briefly, the front stabilizingplate 20-6 is configured to prevent the modular alignment connector 20from being pushed inwardly through the opening 10-13.

FIG. 2C is a rear view of the modular alignment connector 20 and showsthe rear major surface 20-2 which forms a ledge having device stopelements 20-9 extending downwardly therefrom. The device stop elements20-9 have the same or similar function as the serrated stop elements10-60 formed in the interior serrated wall 10-6 of the frame 10.Reference is made to U.S. patent application Ser. No. 13/680,675, filedon Nov. 19, 2012, which is incorporated herein by reference as thoughfully set forth in its entirety, for a more detailed explanation of theframing system that includes the elements (10-60, 20-9) configured tomate with the snap elements formed in the back body portion 102 of themodular devices. All of these elements work together to complete theelectrical enclosure such that the user cannot obtain access to hotelectrical wiring. Moreover, the modular wiring devices 100 is preventedfrom moving laterally within the frame opening when the device snaps aresnapped into place within elements 10-60 and 20-9. Stated briefly, theaforementioned elements work together to secure and align electricalwiring device(s) within the opening 10-13.

FIG. 2D shows the modular connector 20 rotated 180° with respect to theview provided by FIG. 2C. When the connector 20 is installed into theopening 10-13, the bending snap arms 20-3 are deflected inwardly untilthey snap into the serrations 10-60 formed in interior serrated walls10-6. This snap-fit arrangement prevents helps to secure the connector20 within the opening 10-13. Note that when the connector 20 is in thisposition, the rear stabilizing plate 20-7 bears against edges ofconnector landing 10-7 (shown in FIG. 1). Altogether, the snap-arms,front stabilizing plate 20-6 and the rear stabilizing plate 20-7restrict the movement of the modular alignment connector 20 such that itis prevented from moving in or out of the opening 10-13 once theconnector 20 is installed within the opening 10-13.

FIG. 3 is a detail view of the modular alignment connector 20 depictedin FIGS. 2A-2D. This is yet another view of the bending snap arm 20-3,the spacer tang 20-4, and the spacer channel 20-5 therebetween. In thisview, the snap fit arm 20-3 is shown being deflected inwardly as theconnector 20 is being inserted into the opening 10-13. Once thesnap-arms 20-3 snap or deflect outwardly into the serrations 10-60(shown in FIG. 1), the spacer tang 20-4 may be pressed into channel 20-5to lock the modular alignment connector within the opening 10-13.

Referring to FIGS. 4A-4E, illustrative views showing installationdetails of the frame 10, modular alignment connector 20 and electricalwiring device 40 are disclosed. In FIG. 4A, a modular alignmentconnector 20 is shown as being inserted into opening 10-13 of frame 10by the direction of the arrow. Another modular alignment connector isshown as being previously installed at the opposite end of the opening10-13. As depicted in FIG. 4B, both of the modular alignment connectors20 are shown as being installed and locked into the opening 10-13.

In FIG. 4C, a wiring device 100 is shown as being inserted between themodular alignment connectors 20. Note that a portion of the device 100bears against the spacer tangs 20-4. As noted previously, the tangs 20-4are inserted to prevent the snaps 20-3 from disengaging the frameopening 10-13. Once the device 40 is installed, therefore, the spacertangs 20-4 function as a stop that prevents the device 100 from fallingthrough the opening 10-13. Stated differently, once device 100 isinstalled into the frame opening 10-13, the modular alignment connectorsare locked into place and cannot be removed. FIG. 4C also shows a groundwire 10-9 that extends from the ground connection tab 10-8.

FIG. 4D is a side view that shows device 100 being inserted into theframe opening 10-13 by the direction of the arrow. FIG. 4E shows thedevice 100 being fully installed in the frame opening 10-13 withalignment connectors 20 disposed at either end thereof. Reference ismade to U.S. patent application Ser. No. 13/680,675, filed on Nov. 19,2012, which is incorporated herein by reference as though fully setforth in its entirety, for a more detailed explanation of the framingsystem and the method of removing a modular device 100 from the frame.

Referring to FIGS. 5A-5C, various perspective views of the modularelectrical wiring system 500 are disclosed. System 500 is shown toinclude the electrical switching device 100 in combination with theaesthetic overlays 60. The aesthetic overlays are depicted in FIGS. 12,13 and 14, of U.S. patent application Ser. No. 13/680,675 referencedabove. As noted therein, each type of aesthetic overlay (60, 60-20 and60-30) disclosed in the provisional application substantially abuts theadjacent wall surface 1 by virtue of a ratcheting overlay snap 10-3.This feature allows system 500 to accommodate uneven wall surfaces. Asalluded to above, wall box 2 may be a pre-existing wall box disposed ina pre-existing electrical distribution system. Thus, the presentinvention readily accommodates existing installations.

As embodied herein and depicted in FIG. 6, a perspective view of anelectronic wave switch 100 in accordance with one embodiment of thepresent invention is disclosed. Again, like every embodiment of thepresent invention, when the device 100 is inserted into the frameopening 10-13 (see FIGS. 1-4), the user is not exposed to any of theelectrical wiring stowed in the device box. Having said this, theelectronic wave switch 100 includes a wave switch actuator assembly 120coupled to a back body 102. The back body 102 includes heat dissipationvents 102-2. The actuator assembly 120 includes an enclosure portion120-2 that mates with the back body 102 to form a device housing. Theactuator assembly 120 includes an aesthetic cover portion 120-4 that isconnected to the enclosure portion 120-2. An infrared (“IR”) lens 120-6is disposed in the center portion of the aesthetic cover 120-4. The waveswitch device 10 is configured to actuate whenever a user waves his hand(or some other object) in front of the lens 120-6.

Referring to FIG. 7, an exploded view of the electronic wave switch 100depicted in FIG. 6 is disclosed. The electronic wave switch device 100includes an AC power circuit 110 disposed within the back body 102. TheAC power circuit 110 provides power to an electronic actuator circuit112 that is disposed in the wave switch actuator assembly 120. Theelectronic actuator circuit 112 is spaced apart from the AC powercircuit 110. The back body assembly 102 and the AC power circuit 110 areidentical for each of the embodiments disclosed herein.

The back body 102 includes heat dissipation vents 102-2 that allowthermal energy generated by the electronics to vent and dissipate. Snaps102-4 are formed along the perimeter of the back body member 102 and areconfigured to engage frame 10 in the manner described above. Stateddifferently, the electronic wave switch 100 is mounted within the frameand not to the device box; thus, the device 100 does not include anddoes not require a mounting strap. The back body 102 includes an LEDtube 102-6 that is formed in the center portion thereof. The light tube102-6 is configured to accommodate an LED locator light 118 (not shownin the view) that extends through the center portion of the device 100through various openings (110-1, 112-6, etc.). The back body 102 alsoincludes ribbing of various shapes and sizes that accommodate and spaceapart the printed circuit boards (PCBs 110, 112).

The AC power circuit 110 is disposed on a printed circuit board (PCB)110-2 and shown schematically in FIG. 10. The PCB 110-2 includes acentral aperture 110-1 that allows the LED tube 102-6 to extend therethrough. A plurality of terminal structures (104, 106, 108-1, and 108-2)are connected to the PCB 110-2 around its periphery. For example, aground clip terminal 104 is configured to engage the ground connectiontab 10-8 (See FIG. 4C). The ground clip 104 provides the power supplyreturn path (See FIG. 10) with an “earth link” to the frame 10. As shownin FIGS. 4A-4C, the frame 10 includes a ground wire 10-9 that can beattached to the ground tab 10-8 by any suitable means.

The electronic actuator circuit 112 is disposed on PCB 112-2 and isshown schematically in FIGS. 11A-11D. A sensor adjustment aperture112-81 is formed in a corner portion of the PCB 112-2 and accommodatesthe sensor adjustor 112-80. The sensor adjustor 112-80 is coupled to apotentiometer 112-8 (R115), which is also shown in FIG. 11A. Thepotentiometer 112-8 controls the sensitivity of the sensor 112-4 (U102),which is also mounted on PCB 112-2. An IR LED D100 is also mounted onthe PCB 112-2 adjacent to the sensor 112-4 (U102). The function of thesecomponents will be described below in the description of FIG. 11A. Acentral aperture 112-6 is formed in PCB 112-2 and is configured to allowthe LED tube 102-6 to extend there through. The electronic actuator PCB112-2 is positioned within the enclosure 120-2 by several rib elements102-8 formed in the back body 102.

The wave switch actuator assembly 120 includes enclosure portion 120-2,an aesthetic cover 120-4 and an IR lens element 120-6. The enclosureportion 120-2 includes a raised cylindrically shaped plateau 120-20 thatincludes several apertures (120-21, 120-22, 120-26 and 120-28) formedtherein. The LED aperture 120-21 is aligned with an IR LED (D100)mounted on PCB 112-2. The sensor aperture 120-22 is aligned with thesensor integrated chip (IC) U102, which is also mounted on PCB 112-2. Anoblong aperture 120-26 is disposed adjacent to apertures 120-21, 120-22and is configured to receive the locator LED light pipe element 120-8from underneath the enclosure portion 120-2. Snap-holes 120-28 aredisposed at either end of the cylindrical portion 120-20 and areconfigured to accept the snaps 120-62 formed along the periphery of IRlens 120-6. As described below, an aesthetic cover 120-4 and an IR lens120-6 are configured to be connected to enclosure 120-2 to complete theassembly.

Referring to FIG. 8A, a latitudinal cross-sectional view of theelectronic wave switch depicted in FIG. 6 is disclosed. This view showsmore clearly the raised cylindrically shaped plateau 120-20 formed inthe enclosure 120-2. Plateau 120-20 is shown to include the LED aperture120-21 which is aligned with an IR LED (D100) mounted on PCB 112-2. Thesensor aperture 120-22 is also shown as being aligned with the sensorintegrated chip (IC) U102. The sensor adjustor 112-80 is shown as beingcoupled to a potentiometer 112-8 (See also R115 in FIG. 11A). The ACpower PCB 110-2 includes connector J1 mounted on the top surfacethereof. The connector J1 is shown to provide signal connectivity to theactuator circuit PCB 112-2 via lines J1(1-6).

Referring to FIG. 8B, a longitudinal cross-sectional view of theelectronic wave switch depicted in FIG. 6 is disclosed. In thissectional view, the aesthetic cover 120-4 and the locator LED light pipeelement 120-8 are shown. As described below, the LED light pipe 120-8directs light from an LED light source that is inserted from the rear ofthe device 100.

FIGS. 9A-9G are detail views of the cover assembly of the electronicwave switch depicted in FIG. 6. In FIG. 9A, the front aesthetic cover120-4 removed and the IR lens 120-6 is shown as being disposed over thecylindrically shaped plateau 120-20 portion of the enclosure 120-2. InFIG. 9B, the IR lens 120-6 is removed from overtop plateau 120-20 toreveal the oblong aperture 120-26 that accommodates the light pipe120-8. This view also shows the LED aperture 120-21 with the IR LED(D100) there within. The sensor aperture 120-22 is also shown visiblyaligned with the sensor integrated chip (IC) U102. Finally, thesnap-holes 120-28 are shown at either end of the cylindrical portion120-20. As noted above, the snap holes 120-28 accommodate the snaps120-62 for the IR lens cap 120-6.

In reference to FIG. 9C, an underside of the enclosure cover 102-2 isdepicted to illustrate the optical isolation between the locator lightLED 118, the LED D100 and the sensor 112-4 (U102). The size of the LEDaperture 120-21 encloses and isolates the IR LED D100 from the othercomponents. The IR LED aperture 120-21 also prevents the infrared lightthat is emitted from the LED D100 from interfering with the IR Sensor112-4 (U102). Stated differently, LED aperture 120-21 allows the LEDlight to be emitted into the ambient space around the device 100, but italso prevents IR light from bleeding through the plastic in enclosure102-2 to inadvertently cause the IR Sensor 112-4 to actuate the switch.On the other hand, the sensor opening 120-22 is also important. If theopening size is too small, the amount of reflected light is limited suchthat the amount of light directed to the sensor is not sufficient toeffect a desired switch actuation (hand wave). If the opening is toolarge, internal IR light may be reflected by the lens 120-60 andinadvertently actuate the switch. In sum, the opening 120-22 maximizesthe sensor viewing angle of the sensor 112-4 to optimize its ability tosense reflected IR light (i.e., from a hand wave).

Referring to FIG. 9D, a detail view of the sensor adjustor 120-80disposed on PCB 112-2 is disclosed. In this view, the sensor adjustor112-80 is shown on one side of the low voltage PCB 112-2 with thepotentiometer 112-8 being disposed on the other. The sensor adjustor112-80 includes an adjustor dial 112-82 that provides the user withmeans to rotate the sensor adjustor 112-80 when adjusting the sensorsensitivity. FIG. 9E is a detail view that shows the PCB 112-2 with thesensor adjustor 120-80 removed to reveal the sensor adjustment aperture112-81 (which accommodates the sensor adjustor 112-80). The sensoradjustment aperture 112-81 includes a limiter portion 112-83 thatprevents the sensor adjustor 112-80 from being over-rotated (such thatpotentiometer 112-8 is damaged). The potentiometer 112-8 is shown toinclude a keyed opening 112-85 for a longitudinal portion of the sensoradjustor 112-80 (i.e., adjustment key 112-86 shown in FIG. 9F).

FIG. 9F is a rear detail view of the sensor adjustor 112-80. Theunderside of the adjustor dial 112-82 has adjustment key 112-86extending therefrom. The adjustment key 112-86 is formed by asubstantially cylindrical member having a flat surface formed in oneside thereof. The keyed shape mates with the keyed opening 112-85 formedwithin the potentiometer 112-8. Thus, when the dial 112-82 is rotated bya user, the key 112-86 and the keyed opening 112-85 move together toadjust the potentiometer 112-8. The base of the adjustment key 112-86includes an adjustment stop member 112-84. As shown in FIG. 9G, theadjustment stop member 112-84 is configured to engages the limiterportion 112-83 formed in the sensor adjustment aperture 112-81. Asalluded to above, when the stop member 112-84 engages either side of thelimiter portion 112-83, the user is thus prevented from over-rotatingthe sensor adjustor 112-80.

As embodied herein and depicted in FIG. 10A, a schematic diagram of theAC power circuit 110 in accordance with the present invention isdisclosed. As an initial point, the AC power schematic of FIG. 10 showsthat the present invention may be used to realize a three-way switchthat can be used to control a light from two (or more) locations in anAC branch circuit. The terminals are labeled as T-line, 1-Pole, 3-Way,and Ground. T-line may be connected to line or load; and 1-Pole may beconnected to load or line. The ground terminal (i.e., T_EGND) may beimplemented by a ground clip terminal 104 (See, e.g., FIG. 7) thatengages the frame 10 (See, e.g., FIGS. 1-5). The frame 10, of course,includes ground wire 10-9 (See, e.g., FIGS. 4A-B) which is connected tothe premise ground.

In FIG. 10A, the terminal T-Line is shown as being connected to AC powerprovided via an upstream circuit breaker AC PWR. The AC branch circuit,of course, provides a line conductor 2 and a neutral conductor 3. Thebreak in the neutral conductor 3 in FIG. 10A indicates that it isconnected to ground at the breaker box. The terminal T-EGND is connectedto premise ground via the frame 10 as previously described. The terminalT-line is coupled to two traveler conductors T1 and T2 by way of a relay110-4. A positive pulse on signal line “coil+” will throw the relayswitch to traveler T1 whereas a positive pulse on signal line “coil−”will throw the relay switch to traveler T2 (The relay coil actuationcircuit is shown at FIG. 11B). As noted previously, the terminal T-Linecan be connected to a load (e.g., a light element); the load would, ofcourse, be connected to a neutral conductor that extends back to thecircuit breaker CB to complete the circuit.

In any event, both the first traveler T1 and the second traveler T2 areconnected to the power bridge circuit 110-6, a scaling circuit 110-8 andthe calibration circuit 110-20 (See FIG. 10B). The bridge circuit 110-6,of course, provides full wave rectified power to the power supplycircuit 110-10 and is always coupled to AC power via resistor R9 orresistor R4. The scaling circuit 10-8 is configured to provide a currentlimited signal to the zero cross input (ZC) of connector jack J1. Asexplained below, a processor on the low voltage PCB 112-2 uses the zerocross information for signal timing purposes.

The power supply circuit 110-10 includes transistor Q7 which provides acurrent limited source to charge capacitor C1 to about 24 VDC. The 24VDC is provided to power the coil actuator circuit in FIG. 11B. Diode D1clamps the voltage across R23 to limit the charging current to about 0.5mA or less. An unlimited current would damage the circuit during astart-up or charging event. Also since the power supply circuit leakscurrent from either line powered conductor T1 or T2 to earth, it isimportant to limit this current to minimize the effect on upstreamdevices that are sensitive to earth leakage, such as GFCIs. As alludedto above, when a neutral conductor 3 is present in the device box, thepower supply 110-10 may derive power between the traveler conductor T1(or T2) to neutral, instead of to earth ground.

In reference to FIG. 10B, the relay state calibration circuit 110-20 isa NOR circuit that is used to calibrate the electronics (FIG. 11A) toswitch relay 110-4. Stated differently, the purpose of the relay statecalibration circuit is to prevent contact welding by assuring that anyswitch bounce at relay contact closure occurs at or near the “zerocrossing.” The output of the calibration circuit (“relay state”) is alogic one (high) only when the relay switch 110-4 is between the T1 andT2 contacts. Thus, the relay state output is monitored by the processoron the low voltage PCB to measure the time it is a logic one since thisis the time it takes for the relay switch element to move from thetraveler T1 contact to the traveler T2 contact (and vice-versa). Asexplained in more detail below, this value is stored in EEPROM and usedduring relay switching. This feature allows the processor to time therelay switch command such that the relay switch element strikes thetraveler contact (T1 or T2) at precisely the zero crossing of the ACwaveform. At the zero cross moment, there is no current flowing throughthe Line/load conductor given a resistive load, and thus, there will beno arcing as the traveler contact is engaged by the switch relaycontact. As a result, the life of the relay contacts is significantlyextended. Moreover, the size of the relay can be significantly reduced.This feature yields an efficient design because it lowers componentcosts and requires less space.

As embodied herein and depicted in FIGS. 11A-11D, schematic diagrams ofthe low voltage PCB depicted in FIG. 7 are disclosed. In FIG. 11A, thevarious signals from the AC power PCB 110 are provided to the sensor112-4 and the processor 112-6 via the connector jack J100 which iscoupled to the connector jack J1 disposed on the AC power PCB 110. Forexample, the +24 VDC signal is provided to the voltage regulator 112-8(See FIG. 11C). As shown in FIG. 11C, the voltage regulator circuit112-8 (i.e., U100) is a load drop out regulator that creates a lower DCvoltage (3.3 VDC) for the processor 112-6. The regulator 112-8 itself isconfigured to consistently draw 30 uA. In reference to the signalHV_A2D, it is the output of the circuit formed by resistors R100 andR101, and capacitor C101. This circuit measures the bulk supply providedby the regulator 112-8.

Referring back to FIG. 11A, the processor 112-6 (see also 113-6 in FIG.16, and 114-6 in FIG. 20) may be implemented using a “ATtiny 24A”processor as shown in the accompanying drawings. The processor includes2K of flash memory. This IC includes twelve general purpose I/O pins.Pin 1 is connected to VCC, which is provided by the voltage regulator112-8. Lower voltage processors that use 3.3 VDC (compared to 5 VDC) useless power. The processor 112-6 draws approximately 4-6 uA when it is“asleep.” Its current draw when “awake” is about 1-2 mA. The internalclock oscillator of the processor 112-6 runs at 20 MHz. In an alternateembodiment, the internal oscillator runs at 20/8 Mhz. The reason forselecting the oscillator frequency relates to power tradeoff: the lowerfrequency causes less current draw but the instructions take longer toexecute.

It will be apparent to those of ordinary skill in the pertinent art thatmodifications and variations can be made to the processor (112-6, 113-6,or 114-6 shown in the various embodiments of the present invention)depending on a variety of factors including cost, power and speed. Inaddition, the selected processor must perform the core functions of thepresent invention. Many of the pins on the left side of the processor112-6 are used to interface the switch or switch sensor, depending onthe embodiment. Pins 4, 7 and 8 are factory programming pins thatprovide reset, MOSI (“master out slave in”) and MISO (“Master in slaveout”), respectively. The zero cross (ZC) signal and the RELAY STATEsignals are provided to pin 5 and pin 12, respectively, of the processor112-6. As noted above, these signals are used to control the timing ofthe relay switch actuation. The output signal HV_A2D is provided to theanalog to digital input of the processor 112-6. Thus, the processor112-6 monitors the bulk supply and locks out switch actuations that arebelow a certain voltage. This feature ensures that the relay switchclosure times are consistent. The signal 1PB is provided to the relayswitch actuation circuit (FIG. 11B). It has a normally low output, andis driven HIGH for 10 milliseconds to actuate the relay switch solenoid.The signal 1PA also has a normally low output, and it is also drivenHIGH for 10 milliseconds to actuate the reverse solenoid current.

The sensor 112-4 (U102) is an active sensor that is powered by themicro-controller 112-6 output (VCC U102). The processor keeps the sensor112-4 OFF during power-up to speed the charging of C1 (the 220 uFcapacitor.) on the AC power board 110. When the sensor is operational,it turns D100 ON for a short amount of time. The sensor 112-4 (U102) iscoupled to the infrared (IR) LED D100 which is mounted on the PCB 112-2adjacent to sensor 112-4. In operation, the IR LED D100 emits infraredlight at a predetermined frequency. The sensor includes an integralphoto-sensitive element that is configured to receive reflected IRlight. When a person waves his hand or some other object in proximity tothe LED D100, the emitted infrared light is reflected back toward thephoto-sensitive element integrally formed in the sensor 112-4. When thereflected light is received by the sensor 112-4, it is detected by thesensor as being reflected light based on its frequency. However, ambientinfrared light that has different frequency characteristics is ignoredby the sensor since the photosensitive element is attuned to lighthaving a certain frequency (i.e., a unique signature). In any event,when this detection occurs, the signal/INT on pin 7 of the sensor 112-4goes LOW. This signal (/INT) interrupts the processor 112-6, whichinterprets the interrupt as a command to actuate the switch relay. Notethat the mechanical structure of the wave switch actuator assembly 120and its constituent parts prevents cross-talk in multi-ganginstallations.

The present invention is configured to substantially prevent suchcross-talk by way of other means. For example, the sensitivity controldescribed above allows the user to adjust the sensitivity of a switch asneeded. When used alone, the wave switch 100 of the present inventioncan be set to detect motions that are relatively far away from thesensor 112-4. When two or more wave switches are disposed in amulti-gang array, the wave switch 100 can be set to detect motions thatare substantially proximate the sensor 112-4 to prevent unintentionalactuations of adjacent wave switches. The sensitivity adjustments areaccomplished by adjusting the potentiometer 112-8 setting. Thepotentiometer is coupled to the MISO input of the processor 112-6 whichreads the potentiometer setting and provides a corresponding sensitivitysetting to sensor 112-4 by way of the MOSI pin. In an alternateembodiment, an individual wave switch can be equipped with LEDs andsensors that are tuned to different duty cycles (i.e., ON and OFF timesof D100).

As noted above (FIG. 10B), the purpose of the relay state calibrationcircuit is to prevent contact welding by ensuring that any switch bounceat closure occurs at or near the zero crossings (or at any predeterminedpoint in the AC cycle). The processor 112-6 performs an automatedcalibration sequence to achieve this purpose. As explained above, therelay state circuit 110-20 monitors the two travelers and determineswhen the two switch positions are open at the same time. This of courseonly happens when the commutator (moveable)) contact is between the T1and T2 contacts. The relay state circuit 110-20 output goes high whenthe two switch positions are low (NOR gate function). The processor112-6 thus measures the commutator period, i.e., the time it takes forthe commutator to move from the T1 contact to the T2 contact (orvice-versa). The processor 112-6 is also configured to measure the relayswitch contact bounce time and store the time interval (i.e., thecommutator period as measured from commutator start transit until thelast bounce concludes) as a single constant. Alternatively, theprocessor could store the transit time and bounce time as two distinctconstants. The automated calibration sequence can be performed duringproduction or during each operation of the switch by the user, or both.If the automated calibration sequence is performed during production,the relay switch is connected to a pure DC voltage source and the switchis toggled four or five times. Once the constants, have been measured,they are loaded into EEPROM memory. After the switch is sold andconnected to AC power, the solenoid is pulsed relative to the zero cross(ZC) in accordance with the constants stored in memory. In an alternateembodiment of the present invention, an average or estimated commutatortransit time can be pre-stored in memory. The average or estimatedcommutator period may be obtained from the relay switch manufacturer orfrom testing a number of relay switches to obtain an average number.

Turning to FIG. 11B, the current source relay switch actuation circuit112-12 provides the relay switch output signals (COIL+, COIL−) inaccordance with the inputs signals 1PA and 1PB provided by the processor112-6. The relay switch actuation circuit 112-12 includes an “H-bridge”circuit 112-120 and a constant current sink 112-122. The H-bridgecircuit 112-120 includes transistors Q100, Q101, Q108 and Q109. Theoutput COIL+ is disposed at the common collector node between Q101 andQ108. The output COIL− is disposed at the common collector node betweenQ100 and Q109. These outputs are provided to the relay solenoid coil viajack 100.

The input 1PA is provided by the processor 112-6 and is coupled to thebases of the transistors Q105 and Q109, respectively. The transistorQ105 is part of an inverter stage that is coupled to H-bridge transistorQ101. The other input, 1PB, is coupled to the bases of input transistorsQ108 and Q104, respectively. Transistor Q104 is also part of an invertercircuit, and is coupled to H-bridge transistor Q109. The purpose of theinverters is described in greater detail below. The emitters oftransistors Q108 and Q109 are connected to the constant current sink112-122. Taken together, these circuits provide the relay switch 110-4with a constant current source.

The operation of the constant current source is as follows. Theprocessor controlled signals 1PB and 1PA are never ON at the same time.When the processor drives the input control signal 1PA HIGH, the relaycommutator is driven in one direction, and when it drives 1PB HIGH, thecommutator is driven in the opposite direction. Thus, only one operation(1PA or 1PB) of the constant current source (112-20, 112-22) need bedescribed. When 1PA is driven HIGH, transistors Q109 and Q105 are turnedON because they are NPN transistors. Q105 is an inverter which drivesthe base of transistor Q101 LOW. Since Q101 is a PNP transistor, it isturned ON. As a result, current flows from the +24 V supply and into theCOIL+ input of the relay 110-4 via transistor Q101. The current returnsto the H-bridge circuit 112-20 via the node COIL− and flows through Q109to the constant current sink circuit 112-122.

At this point, the current flows through resistor R111 to the base oftransistor Q102, turning it ON, such that current flows through resistorR112. When the voltage across resistor R112 reaches a predeterminedthreshold (e.g., about 0.6-0.7 V) the transistor Q103 also turns ON todivert current away from the base of transistor Q102 such that thevoltage across R112 is substantially constant. Stated differently, theresistor R112 controls the constant current source by maintaining thecurrent flow through Q102. The constant current sink 112-22 thusregulates the current flowing through the relay switch 110-4 (via outputnodes COIL+, COIL−). Again, the constant current source 112-12 isemployed to obtain consistent commutator periods (commutator transittimes between T1 and T2). Again the constant current sink 112-22 worksin the same manner for both the 1PA and the 1PB actuations.

The consistent commutator periods hold true even if the switch isactuated by the user in rapid succession, e.g. once a second. Using thetap switch embodiment (FIGS. 12-16) as an example, any user input fromS100 (FIG. 16) will yield a predictable sequence. The level of constantcurrent multiplied by the solenoid impedance yields 12 VDC. Thus, theconstant current source discharges C1 to not less than 12 VDC during the10 millisecond pulse interval while, at the same time, the currentremains constant.

In an alternate embodiment, the constant current source may beeliminated by locking out user switch actuations to less than, e.g., 2second intervals. In this embodiment, the relay would always beenergized via decaying exponential voltage starting at 24 VDC. In yetanother alternate embodiment that can be employed with inductive loads,the processor is configured to close the relay at the optimum phaseangle for the anticipated inductive or capacitive loads. Thus, theautomated calibration would take the load phase shift into account.

In reference to FIG. 11D, the processor can be programmed using signalsMISO, MOSI which are present on jack J101.

As embodied herein and depicted in FIGS. 12A-12B, perspective views ofan electronic tap switch 100 in accordance with another embodiment ofthe present invention is disclosed. FIG. 12A shows a top perspectiveview of the tap switch 100. The tap switch device 100 includes tapswitch cover assembly 130 coupled to the back body member 102. The toplayer of the cover assembly 130 is the changeable decorative cover 130-6which snaps into the functional actuator 130-4 (not shown) using snaps130-62. The circular lens 130-60 is a relatively thin portion of thecover 130-6 that allows light emitted by the separate LED locator light118 (not shown in this view) which is configured to transmit light intothe ambient environment around the cover assembly 130-6 when the device100 is installed and energized.

FIG. 12B shows the rear perspective view of the tap switch 100 whichshows the back body member 102. The back body 102 is identical to theone shown in FIGS. 6-9. The light tube 102-6 is configured toaccommodate the LED locator light 118 (not shown in the view). As notedpreviously, the LED locator light 118 extends through the center portionof the device 100 via locator light tube 102-6. The center aperture130-40, of course, accommodates the LED locator light 118 that extendsthrough the tube 102-6. As noted previously, there are correspondingapertures in the AC power PCB 110 and the low power voltage PCBs 112,113 and 114).

In reference to FIGS. 13A-13B, detail views of the tap switch functionalactuator 130-4 and the enclosure 130-2 are more clearly depicted. Thefunctional actuator 130-4 includes slidable snaps 130-44 that areconfigured to snap into apertures 130-24 of enclosure layer 130-2 (SeeFIG. 13B). At the opposite end, the functional actuator 130-4 includeshinge elements 130-42 which are configured to snap into the hingereceptors 130-22 formed in the enclosure layer 130-2. The functionalactuator 130-4 further includes a switch boss 130-41 which is configuredto extend through boss aperture 130-21 of the enclosure layer 130-2. Theenclosure layer 130-2 further includes leaf spring elements 130-26 whichcauses the switch boss 130-41 of functional actuator 130-4 to disengagefrom the tap switch S100 disposed on the low voltage board 113 (See FIG.14) after the user has finished depressing the tap switch.

In reference to FIG. 14, an exploded view of the electronic tap switch100 depicted in FIGS. 12-13 is disclosed. Again, the decorative cover130-6 snaps into the functional actuator 130-4 using snaps 130-62. Aswitching axis is shown extending from the switch boss 130-41, throughboss aperture 130-21, and to the tap switch S100 disposed on the lowvoltage tap switch board 113. Taking FIGS. 12-14 together, thefunctional actuator 130-4 is shown to be fixed at one end by the hingemembers (130-24, 130-44) and the switch actuator 130-4 rotates about thehinge axis such that switch boss 130-41 can slidably move within bossaperture 130-21 to actuate the tap switch 100 disposed underneath on thelow voltage PCB 113. The low voltage tap switch board 113 receives powerfrom the AC power PCB 110 which is disposed in the back body 102. Thesame AC power PCB 110 and the same back body 102 are used in the waveswitch embodiment (FIGS. 6-9) and the instant embodiment.

FIGS. 15A-15D are cross sectional views of the electronic tap switchdepicted in FIGS. 12-14. FIG. 15A provides a longitudinalcross-sectional view that shows the slidable snap 130-44 disposed in theaperture 130-24. At the opposite end, the hinge 130-42 is shown as beingdisposed in the hinge receptors 130-22. In the mid-portion in betweenthe ends, the leaf spring 130-26 can be seen supporting the functionalactuator 130-4. In FIG. 15B, a second longitudinal cross-sectional viewis provided. This view shows the second set of slidable snaps andhinges.

FIG. 15 C provides a latitudinal cross-section that extends through thetap switch S100 and the center light tube 102-6. This view illustrateshow the switch boss 130-41 extends through boss aperture 130-21 toactuate the electronic switch S100. In addition, the decorative cover130-6 is shown to include a light window or lens 130-60 formed therein.The lens 130-60 may be mechanically machined or etched out by a laser.

FIG. 15D is another longitudinal cross-section of the tap switch 100. Inthis view, the tap switch 100 is shown mounted to the frame 10 (FIGS.1-4). The device box is not shown in this view for clarity ofillustration. However, a person having ordinary skill in the art willunderstand that the back body 102 of the device is housed within thedevice box. Moreover, as described previously, the frame 10 is coupledto the device box and the device 100 is snapped into the frame 100 suchthat the various terminals automatically make connection to theconnection tabs provided by the frame 10. For example, this view showsthe device 100 ground tab 10-8 engaging the ground connection tab 104.Once the device is installed within the frame 10, then the user willconnect the aesthetic cover plate 60 to the frame. Each type ofaesthetic overlay (60, 60-20 and 60-30) substantially abuts the adjacentwall surface 1 by virtue of a ratcheting overlay snap 10-3.

As embodied herein and depicted in FIG. 16, a schematic diagram ofrelevant portions of the low voltage PCB 113 depicted in FIG. 13 aredisclosed. With the exception of the switch 113-4 (S100) and theprocessor 113-6, this circuit is identical to the one shown in FIG. 11A.Stated differently, the switch 113-4 replaces the sensor 112-4 (in FIG.11A) and the processor 113-6 replaces the processor 112-6 (in FIG. 11A).While both processors can be implemented using the same hardware, thesoftware may be different since one embodiment responds to sensoractuation and the other embodiment responds to switch actuation. In anyevent, when the user wishes to change the state of the lighting load, heor she merely taps the decorative plate 130-6 such that the switchbutton 113-4 (S100) is depressed. The processor reads the interrupt muchlike it did in the previous embodiment. Once the processor 113-6 sensesthe interrupt signal it provides the signals 1PA and 1PB to the relayswitch actuation circuit 112-12 (See FIG. 11B) in accordance with thetiming signals ZC and RELAY STATE as described previously.

As embodied herein and depicted in FIGS. 17A-17B, perspective views ofan electronic touch switch in accordance with yet another embodiment ofthe present invention is disclosed. FIG. 17A shows a top perspectiveview of the touch switch 100. The touch switch device 100 includescosmetic cover assembly 140 coupled to the back body member 102. The toplayer of the cover assembly 140 includes a circular lens 140-60 is arelatively thin portion of the cover 140-6 that allows light emitted bythe separate LED locator light 118 (not shown in this view) which isconfigured to transmit light into the ambient environment around thecover 140-6 when the device 100 is installed and energized.

FIG. 17B shows the rear perspective view of the touch switch 100 whichfeatures the back body member 102. The back body 102 is identical to theone shown in the previous embodiments. The light tube 102-6 isconfigured to accommodate the LED locator light 118. As shown herein,the LED locator light 118 extends through the center portion of thedevice 100 via tube 102-6.

Referring to FIG. 18, an exploded view of the electronic touch switchdepicted in FIGS. 17A-17B is shown. The cover assembly 140 includes adecorative cover 140-6 that has a clear plastic top layer 140-62 bondedto a colored under layer 140-64. The purpose of this arrangement is toprovide the decorative cover with the perception of depth. Again, thelens aperture 140-60 is a narrow region in the center of the cover140-6. The decorative cover 140-6 is coupled to a major surface 140-22of the cover enclosure 140-2 by an adhesive layer 140-4. The adhesivelayer 140-4 includes a central aperture 140-40 that allows the LEDlocator light 102-18 to emit light there through. The cover enclosure140-2 also includes a thin lens region 140-20. The cover enclosure alsohouses an antenna assembly 116 that includes an antenna 116-22 disposedon a printed circuit board 116-2. The antenna 116-22 is coupled to a via116-24 which couples the antenna 116-22 to the low voltage PCB 114 viaan interconnection wire 114-24. Of course, the antenna PCB 116-2includes a central aperture 116-20 that accommodates the LED locatorlight 118.

As before, the low voltage signal processing assembly 114 includes a PCB114-2 that includes a central aperture that accommodates the LED locatorlight 118. And as before, the low voltage PCB 114-2 is connected to theAC power board 110 by the interconnection of jacks J1 and J100.Moreover, the AC board 110 is identical to the AC PCBs 110 used in theprevious embodiments. Finally, like the previous two embodiments, the ACPCB 110 and the low voltage PCB 114-2 are housed within the back bodymember 102.

Referring to FIGS. 19A-19C, cross sectional views of the electronictouch switch 100 depicted in FIGS. 17-18 are disclosed. FIGS. 19A and19B are directed to longitudinal cross-sectional views of the touchswitch 100. FIG. 19A shows the switch with the LED locator light 118inserted into the tube 102-6 whereas FIG. 19B shows the locator light118 removed from the tube 102-6. This view shows all of the lenses(140-20, 140-60) in alignment. FIG. 19C is another longitudinalcross-sectional view of the touch switch 100. This view shows the groundterminal 104 accessible from the back body 102. As explained above, theground terminal 104 is a flexible element that is configured to makecontact with the frame 10 (which is coupled to premise ground).

Note that the antenna board 116 abuts the underside of the coverenclosure 140-22. As depicted in FIG. 18, the antenna 116-22 is actuallya copper grid or mesh disposed on PCB 116-2. The copper mesh implementsa “single ended” electrode, or conductor. The copper area creates acapacitance with respect to neighboring grounds; this capacitance isdefined as the load capacitance. As explained previously, the coppermesh and PCB is disposed under the cover enclosure 140-2. The loadcapacitance is typically below about 20 pf since the load capacitancecan affect the rise and fall times of the burst patterns generated bythe sensor test signal (SNSK). The test signal creates an E-field; andthe E-field must be an appropriate distance from ground. This distanceis implemented by placing the copper mesh on a separate PCB under thecover enclosure 140-2, and implementing a ground plane about ⅛ inchesaway on the low voltage PCB 114-2. When a person's finger approaches theactuator, the person's body provides the capacitance that changes the Efield. In another embodiment of the invention the ground plane isimplemented on the underside of PCB 116-2 made about ⅛ inch thick.

Referring to FIG. 20, a schematic diagram of the low voltage PCB 114 ofthe electronic touch switch depicted in FIG. 18 is disclosed. Again,only the sensor 114-4 and the processor 114-6 are shown because all ofthe other components are identical to what is shown in the firstembodiment. The sensor 114-4 (U102) is an active sensor that is poweredfrom the processor 114-6 via the “VCC-U102” output. One reason for thisarrangement is that the processor 114-6 can remove power from the sensor114-4 during power-up such that the charging of the +24 VDC power supplyoutput (i.e., capacitor C1 in FIG. 10A) can be expedited. The sensor114-4 (U102) is coupled to the antenna 116-22 by capacitor C105 andresistor R102. In operation, when a person's finger touches thedielectric plate 140-22, the capacitance changes significantly becausethe circuit is configured in such a way that the capacitive effects ofthe finger dominate. When the sensor 114-4 detects the change incapacitance, the sensor OUT (pin 1) goes LOW to provide a signalinterrupt to the processor 114-6. As before, the interrupt isinterpreted as a command to actuate the switch relay. Once the processor112-6 senses the interrupt signal it provides the signals 1PA and 1PB tothe relay switch actuation circuit (FIG. 11B) in accordance with thetiming signals ZC and RELAY STATE as described previously.

In one embodiment of the present invention, the sensor 114-4 isimplemented as an integrated circuit chip (“AT42QT1010”) manufactured byATMEL CORPORATION. This IC is a momentary responding device thatprovides a HIGH output signal when a person's finger is touching orproximate the plate (140-62). Stated differently, SNSK output provides aperiodic pulse train at a first frequency (f₁) across the measuringcapacitor C105. When a human finger touches the plate (140-62) or isclose to touching it, the capacitance across capacitor C105 changes suchthat the signal presented on the OUT pin is a logic HIGH. The processorreads this logic HIGH as an interrupt and a command to switch the relay.Once the finger is no longer touching or proximate the plate, the OUTpin signal is a logic LOW.

In another embodiment, the sensor 114-4 is configured to include aserial data input pin similar to the one employed by sensor 112-2 inFIG. 11A. Much like the previous embodiment, the potentiometer 112-8 (Asper FIG. 11A) is connected to the MISO input of processor 114-6. Theprocessor output port (MISO) is connected to the serial data input portof the alternate embodiment sensor 114-4 to thereby provide it withsensitivity adjustment data such that the sensitivity of the capacitivesensor can be adjusted. For example, the user may become annoyed if theswitch is actuated when a person, or the person's shoulder inadvertentlybrushes by the switch. On the other hand, the user may desire to raisethe sensitivity when the required touch is too heavy or pronounced.

In an alternate embodiment of the invention, the sensor 114-4 isconfigured as a latching device. Once the sensor output is driven HIGH,it will remain that way until the user touches the plate again. Thus,the processor is programmed to switch the relay when transitions occur(LOW to HIGH, or HIGH to LOW).

As embodied herein and depicted in FIG. 21, an exploded view of themodular electrical wiring system in accordance with yet anotherembodiment of the present invention is disclosed. In this embodiment,the three types of electronic switches are interchangeable. The switchesare interchangeable at the factory or may be configured to beinterchangeable by the user. Stated differently, the electronic switchfunctionality implemented on the low voltage PCB is disposed within theswitch module 150. The decorative cover 150-6 of the module would beused to implement the wave switch (FIGS. 6-9 and 11), the tap switch(FIGS. 12-16) or the touch switch (FIGS. 17-20). The power supply isprovided by the separator assembly 103, which is inserted over the ACpower PCB (FIG. 10) disposed in the back body 102. FIG. 22 is a detailexploded view of the modular electrical wiring system shown in FIG. 21.As shown, the back body 102 is sized as a three-module (i.e., a singlegang size) device and easily accommodates the AC power PCB 110 (See FIG.10). The separator assembly 103 includes alignment connectors 103-2 thatmate with the separator side portions 103-40 and 103-41 at either endthereof. The separator 103-4 includes a jack 103-42 that functions muchlike J1/J100 (FIGS. 10-11). The AC circuit (FIG. 10) is disposed underthe separator floor 130-46 which is separated from the floor of the backbody 102 by stand-off elements 103-44.

The present invention may be implemented using a standard wiring deviceform factor. FIG. 23 is a front view of an electronic switch 160 inaccordance with yet another embodiment of the present invention. In thisembodiment, a wave, tap and touch switch embodiments with a centrallydisposed locator light 160-2 are disclosed. FIG. 24 is a front view ofan electronic switch 170 in accordance with yet another embodiment ofthe present invention. In this embodiment, a wave, tap and touch switchembodiments without a centrally disposed locator light are disclosed.

As embodied herein and depicted in FIGS. 25A-25D, various embodiments ofLED locator lenses 250 are disclosed. While the embodiments describedbelow use the decorative cover 130-6 as an example, one skilled in theart will understand that any of the decorative covers (120-6, 130-6,140-6, and 150-6) may employ any one of the locator lens embodimentsdescribed below. Moreover, it should be understood that any of thefollowing embodiments may be used to implement any of the lensespreviously depicted herein (e.g., lens 130-60 in FIG. 12A, lens 140-60in FIG. 17A, or lens 160-2 in FIG. 23).

Referring to FIG. 25A, one embodiment of the LED locator lens 250 inaccordance with the present invention is disclosed. Locator lens 250includes a circular stepped region 250-2 formed in rear surface of thedecorator cover 130-6 proximate the LED locator light 118. As shown, thecross-sectional thickness within the stepped region is relatively thin,at about 0.020 inches. The stepped region 250-2 is formed by injectionmolding or by another similar process. The front portion of thedecorator cover is painted with a dark gray paint 250-4 that issubstantially opaque. The paint layer 250-4 is laser etched to reveal athin layer of translucent material in an annular ring region 250-6 thatis sometimes referred to as the “bull's eye.” Since the paint 250-4 isremoved and the plastic region 250-2 is relatively thin, when light isemitted by locator LED 118, the annular ring 250-6 is illuminated forthe user. Obviously, if the optional LED locator light 118 is notinstalled here or in other embodiments, the so-called “bull's eye” willstill be visible to the user even though it is not back-lit by thelocator light 118.

Referring to FIG. 25B, another embodiment of the LED locator lens 250 isdisclosed. Like the previous embodiment, the locator lens 250 includes acircular stepped region 250-2 that is formed in rear surface of thedecorator cover 130-6 proximate the LED locator light 118. In thisversion, the front surface of the decorator cover 130-6 is not painted.The outside surface is of a uniform color except where the covermaterial is etched by a laser to form an annular ring pattern 250-6. Inthis case, when the material is etched, it changes to a darker color orless translucent. Thus, the annular ring 250-6 is not illuminated whenthe locator light 118 is ON. Instead, the region 250-60 inside theannular ring 250-6 is translucent and illuminated when the LED 118 isON. In addition, the region 250-62 outside the annular ring 250-6 mayprovide a lesser degree of illumination when the LED 118 is emittinglight. This is especially true if the outside diameter of the steppedregion 250-2 is greater than the outside diameter of the annular ring250-6. Although the laser etch has darkened the plastic in the annularring 250-6, this region is typically not fully opaque.

Referring to FIG. 25C, yet another embodiment of the LED locator lens250 is disclosed. In this embodiment, the locator lens 250 includes acircular stepped region 250-2 formed in the front surface of thedecorator cover 130-6 proximate the LED locator light 118. The steppedregion 250-2 in this embodiment is also formed by an injection moldingprocess or an equivalent. Again, the cross-sectional thickness withinthe stepped region is relatively thin, at about 0.020 inches. Like theembodiment of FIG. 25A, the front portion of the decorator cover ispainted with a dark gray paint 250-4 that is substantially opaque. Thepaint layer 250-4 is laser etched to reveal a thin layer of translucentmaterial in the annular ring region 250-6. Since the paint 250-4 isremoved and the region 250-2 is relatively thin, the annular ring 250-6is illuminated when light is emitted by locator LED 118.

Referring to FIG. 25D, yet another embodiment of the LED locator lens250 is disclosed. Like the embodiment, of FIG. 25C, the locator lens 250includes a circular stepped region 250-2 formed in the front surface ofthe decorator cover 130-6 proximate the LED locator light 118. Like theembodiment of FIG. 25B, the front surface of the decorator cover 130-6is not painted. The outside surface is of a uniform color except wherethe cover material is etched by a laser to form an annular ring pattern250-6. When the material is etched, it changes to a darker color orbecomes less translucent. Thus, the annular ring 250-6 is notilluminated when the locator light 118 is ON. Instead, the region 250-60inside the annular ring 250-6 is translucent and illuminated when theLED 118 is ON. Moreover, the region 250-62 outside the annular ring250-6 may provide a lesser degree of illumination when the LED 118 isemitting light if the outside diameter of the stepped region 250-2 isgreater than the outside diameter of the annular ring 250-6. Althoughthe laser etch has darkened the plastic in the annular ring 250-6, thisregion is typically not fully opaque.

The bull's eye feature shown in conjunction with the family ofelectronic switches described herein, may also be incorporated in otherwiring devices including those that employ the framing system depictedin FIGS. 1-5.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. The term “connected” is to beconstrued as partly or wholly contained within, attached to, or joinedtogether, even if there is something intervening.

The recitation of ranges of values herein are merely intended to serveas a shorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein.

All methods described herein can be performed in any suitable orderunless otherwise indicated herein or otherwise clearly contradicted bycontext. The use of any and all examples, or exemplary language (e.g.,“such as”) provided herein, is intended merely to better illuminateembodiments of the invention and does not impose a limitation on thescope of the invention unless otherwise claimed.

No language in the specification should be construed as indicating anynon-claimed element as essential to the practice of the invention.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present inventionwithout departing from the spirit and scope of the invention. There isno intention to limit the invention to the specific form or formsdisclosed, but on the contrary, the intention is to cover allmodifications, alternative constructions, and equivalents falling withinthe spirit and scope of the invention, as defined in the appendedclaims. Thus, it is intended that the present invention cover themodifications and variations of this invention provided they come withinthe scope of the appended claims and their equivalents.

What is claimed is:
 1. An electronic switch device for controlling aload, the device comprising: a housing assembly including a front coverassembly having a user interface, a back body assembly, and a pluralityof terminals configured to be coupled to an AC power source and theload; a circuit assembly coupled to the plurality of terminals, thecircuit assembly including a relay switch having a commutator and a setof contacts, the relay switch being characterized by a predeterminedcommutator period, the predetermined commutator period beingsubstantially a commutator travel time between the set of contactsduring a relay switch actuation, the circuit assembly further includingan actuation circuit having a current source configured to provide apredetermined constant current actuation signal to effect thepredetermined commutator period, the actuation circuit energizing therelay switch in response to an input stimulus via the user interfacesuch that an end of the predetermined commutator period substantiallycoincides with a predetermined point in an AC power cycle.
 2. The deviceof claim 1, wherein the predetermined point in an AC power cyclecorresponds to a zero crossing of the AC power cycle.
 3. The device ofclaim 1, wherein the predetermined point corresponds to a predeterminedphase shift relative to a zero crossing of the AC power cycle.
 4. Thedevice of claim 3, wherein the predetermined phase shift corresponds toan inductive load.
 5. The device of claim 3, wherein the predeterminedphase shift corresponds to a capacitive load.
 6. The device of claim 1,wherein the circuit assembly is configured to measure the commutatorperiod of the relay switch.
 7. The device of claim 6, wherein thecommutator period is measured before the device enters the stream ofcommerce during a calibration procedure and is stored in the circuitassembly.
 8. The device of claim 6, wherein the commutator period ismeasured from time to time after the device enters the stream ofcommerce.
 9. The device of claim 8, wherein the commutator period ismeasured by a processor and stored in memory, the processor and memorybeing included in the circuit assembly.
 10. The device of claim 1,wherein the commutator period is an estimated value.
 11. The device ofclaim 1, wherein the commutator period is an average value derived frommeasuring a plurality of the relay switches during a calibrationprocedure.
 12. The device of claim 1, wherein the circuit assemblyincludes a command input circuit coupled between the user-interface andthe actuation circuit, the command input circuit being configured topropagate a switch actuation command in response to detecting the inputstimulus.
 13. The device of claim 12, wherein the command input circuitincludes an electronic push button switch coupled to the user interface.14. The device of claim 12, wherein the command input circuit includes asignal receptor portion and coupled to the user interface, the signalreceptor portion being configured to sense perturbations in a signalparameter.
 15. The device of claim 14, wherein the signal receptorportion includes a photo-sensitive element configured to measure lightreflected from a light emitting diode (LED).
 16. The device of claim 15,wherein the light emitted from the LED is infrared light.
 17. The deviceof claim 15, wherein the signal parameter includes a pulse trainfrequency.
 18. The device of claim 14, wherein the command input circuitcoupled between the user-interface and the actuation circuit is a waveswitch.
 19. The device of claim 14, wherein the command input circuitcoupled between the user-interface and the actuation circuit is a touchswitch.
 20. The device of claim 14, wherein the signal receptor portionincludes a capacitive sensor configured to measure changes incapacitance.
 21. The device of claim 14, wherein the circuit assemblyincludes a sensor detector coupled to the signal receptor portion, thesensor detector being configured to determine whether the perturbationsof the signal parameter correspond to a switch actuation command inaccordance with a sensor detection rule.
 22. The device of claim 21,wherein the circuit assembly also includes a processing circuitconfigured to drive the actuation circuit in response to the switchactuation command.
 23. The device of claim 22, wherein the sensordetection rule is implemented by an algorithm executed by the processingcircuit.
 24. The device of claim 22, wherein the command input circuitincludes a sensor sensitivity adjustment interface coupled to theprocessing circuit, the processing circuit being configured to adjustthe sensor detection rule in accordance with a setting of the sensorsensitivity adjustment interface.
 25. The device of claim 21, whereinthe sensor detection rule includes a predetermined threshold.
 26. Anelectrical wiring system comprising a frame member configured to beconnected to a device box, the frame member including a frame openingsubstantially conforming to the housing assembly of the device of claim1 such that the device box enclosure is substantially completed when thedevice of claim 1 is secured within the frame opening.
 27. The system ofclaim 26, further comprising at least one modular alignment connectordisposed within the frame opening adjacent the device of claim 1,wherein the at least one modular alignment connector and the device ofclaim 1 complete the device box enclosure when the device of claim 1 andthe at least one modular alignment connector are secured within theframe opening.
 28. The system of claim 26, wherein the device of claim 1is secured to the frame member but not to the device box.
 29. The systemof claim 26, further comprising an aesthetic cover plate configured tobe coupled to the frame member, the aesthetic cover plate including aplate opening that is configured to expose the user interface of thedevice of claim 1 when the aesthetic cover plate is coupled to the framemember.
 30. The device of claim 1, further comprising a mounting strapconfigured to secure the device to a device box during deviceinstallation.
 31. An electronic switch device comprising: a housingassembly including a plurality of terminals configured to be coupled toan AC power source and a load, the housing assembly also including auser interface and a sensitivity adjustment interface; a circuitassembly coupled to the plurality of terminals, the circuit assemblyincluding a current source configured to provide a predeterminedconstant current actuation signal and a relay switch, the relay switchhaving a commutator and a set of contacts, the relay switch beingcharacterized by a commutator period, the commutator period beingsubstantially a commutator travel time between the set of contacts, thecircuit assembly also including a sensor detector receptor portioncoupled to the user interface and configured to sense perturbations of asignal parameter, the circuit assembly also including a sensor detectorcoupled to the sensor receptor portion, the sensor detector beingconfigured to determine whether the perturbations of the signalparameter correspond to a switch actuation command in accordance with adetection rule, the circuit assembly also including a regulation circuitcoupled to the sensitivity adjustment interface and the sensor detector,the regulation circuit being configured to adjust the detection rule inaccordance with a setting of the sensitivity adjustment interface anddirect the relay switch to actuate in response to the switch actuationcommand in accordance with a selected sensitivity adjustment.
 32. Thedevice of claim 31, wherein the sensor receptor portion includes aphoto-sensitive element configured to measure light reflected from alight emitting diode (LED).
 33. The device of claim 32, wherein thesensitivity adjustment interface is configured to adjust a sensitivityof the photosensitive element.
 34. The device of claim 32, wherein thesignal parameter is selected from a group of parameters that includes apulse train frequency, a light frequency, an amplitude, or a duty cycle.35. The device of claim 31, wherein the sensor receptor portion includesa capacitive sensor configured to measure changes in capacitance. 36.The device of claim 35, wherein the sensitivity adjustment interface isconfigured to adjust a sensitivity of the capacitive sensor.
 37. Thedevice of claim 31, wherein the sensor receptor portion includes anelectronic switch, and wherein the detection rule includes a switchclosed time duration greater than a predetermined time interval.
 38. Thedevice of claim 31, wherein the constant current actuation signal isconfigured to energize the relay switch in response to a regulationcircuit directive such that an end of the predetermined commutatorperiod substantially coincides with a predetermined point in an AC powercycle.
 39. The device of claim 38, wherein the predetermined point in anAC power cycle substantially corresponds to a zero crossing of the ACpower cycle.
 40. The device of claim 38, wherein the predetermined pointcorresponds to a predetermined phase shift relative to a zero crossingof the AC power cycle.
 41. The device of claim 40, wherein thepredetermined phase shift corresponds to an inductive load.
 42. Thedevice of claim 40, wherein the predetermined phase shift corresponds toa capacitive load.
 43. The device of claim 38, wherein the circuitassembly is configured to measure the commutator period of the relayswitch.
 44. The device of claim 43, wherein the commutator period ismeasured before the device enters the stream of commerce during acalibration procedure.
 45. The device of claim 43, wherein thecommutator period is measured from time to time after the device entersthe stream of commerce.
 46. The device of claim 45, wherein thecommutator period is measured by a processor and stored in memory, theprocessor and memory being included in the circuit assembly.
 47. Thedevice of claim 38, wherein the commutator period is an estimated value.48. The device of claim 38, wherein the commutator period is an averagevalue derived from measuring a plurality of the relay switches during acalibration procedure.
 49. The electronic switch device of claim 31,wherein the commutator period is accomplished by applying thepredetermined constant current actuation signal to the relay switch. 50.An electronic switch device configured to be installed within a devicebox, the device comprising: a housing assembly including a plurality ofterminals configured to be coupled to an AC power source, the housingassembly further including a first circuit assembly coupled to theplurality of terminals, the first circuit assembly including a relayswitch having a commutator and a set of contacts, the relay switch beingcharacterized by a commutator period, the commutator period beingsubstantially the commutator travel time between the set of contacts;and an interchangeable switch module configured to be coupled anddecoupled from the housing assembly, the interchangeable switch modulebeing selected from a plurality of interchangeable switch modules, eachinterchangeable switch module being characterized by a user interfacethat is implemented by one of a plurality of switching technologies, theinterchangeable switch module also including a second circuit assemblycoupled to the first circuit assembly when the interchangeable switchmodule is coupled to the housing assembly, the second circuit assemblypropagating a constant current actuation signal that energizes the relayswitch in response to an input stimulus via the user interface such thatan end of the predetermined commutator period substantially coincideswith a predetermined point in an AC power cycle.
 51. The device of claim50, wherein the housing assembly includes a separator portion disposedin a back body assembly, the separator portion including at least onefirst connector jack configured to provide electrical circuit pathsbetween the housing assembly and the interchangeable switch module. 52.The device of claim 50, wherein one of a plurality of user-interfacesincludes an electronic push button switch coupled to the second circuitassembly.
 53. The device of claim 50, wherein one of a plurality ofuser-interfaces includes a wave switch assembly coupled to the secondcircuit assembly.
 54. The device of claim 50, wherein one of a pluralityof user-interfaces includes a touch switch assembly coupled to thesecond circuit assembly.
 55. An electrical wiring system comprising aframe member configured to be connected to a device box, the framemember including a frame opening substantially conforming to the housingassembly of the device of claim 50 such that the device box enclosure issubstantially completed when the device of claim 50 is secured withinthe frame opening.
 56. The system of claim 55, further comprising atleast one modular alignment connector disposed within the frame openingadjacent the device of claim 50, wherein the at least one modularalignment connector and the device of claim 50 complete the device boxenclosure when the device of claim 50 and the at least one modularalignment connector are secured within the frame opening.
 57. The systemof claim 55, wherein the device of claim 50 is secured to the framemember but not to the device box.
 58. The system of claim 55, furthercomprising an aesthetic cover plate configured to be coupled to theframe member, the aesthetic cover plate including a plate opening thatis configured to expose the user interface of the device of claim 50when the aesthetic cover plate is coupled to the frame member.